2013 03-12-masterclass-biomedical-applications-of-am sirris-ad_dtechnic

Part 03 : Technical aspects

Biomedical applications of Additive Manufacturing

Masterclass:

Magnien Julien

Context sensitization Additive Manufacturing principle Description of the different AM technologies Technologies comparison Well suited applications cases Conclusions

Organized by SIRRIS the 12th of March 2013 Masterclass: Biomedical applications of Additive Manufacturing 2

The traditional ways to manufacture parts are : Machining : remove material from a bloc larger than the part itself. This is

a « subtractive » way.

Injection/molding : build a mold and place a melted material inside which will solidify.


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http://www.google.be/url?sa=i&rct=j&q=metalworking&source=images&cd=&cad=rja&docid=0VmwB-HnbAntsM&tbnid=QKD5UnZVWDuWnM:&ved=0CAUQjRw&url=http://www.cimindustry.com/product/chipping/synthetic-metalworking-fluid&ei=lBk3UautM62U0QWM64HICQ&bvm=bv.43287494,d.ZWU&psig=AFQjCNHpTSFEmkY0b0ijGD_HpgoLvRaftQ&ust=1362651850162733�

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http://www.google.be/url?sa=i&rct=j&q=Electrical+discharge+machining&source=images&cd=&cad=rja&docid=S39SL82rhfFQCM&tbnid=8EsjKa18FpFpjM:&ved=0CAUQjRw&url=http://la.epfl.ch/page-70059-en.html&ei=Gxs3UZTUN8yY1AXS_IGYCA&bvm=bv.43287494,d.ZWU&psig=AFQjCNG85Y4fffF6N7bR7-Tz54fvuzJvmg&ust=1362652259384816�

http://www.google.be/url?sa=i&rct=j&q=mold+injection&source=images&cd=&cad=rja&docid=FPzlRtiDxnbuTM&tbnid=Lb2KrhAe9BBCHM:&ved=0CAUQjRw&url=http://pdipaxton.com/injection-molding/&ei=nR03UebvK-GO0AWH2oHACA&bvm=bv.43287494,d.ZWU&psig=AFQjCNEak1_Q4EOEqGbGKasB48OPp-mNjQ&ust=1362652890688497�

http://www.google.be/url?sa=i&rct=j&q=foundry&source=images&cd=&cad=rja&docid=PfeUFzOajpkV4M&tbnid=8qNCFalYwzrb1M:&ved=0CAUQjRw&url=http://www.dreamstime.com/stock-photos-foundry-molten-metal-pour-image19696003&ei=Ox43Ue7KIsab1AXpsIDgDw&bvm=bv.43287494,d.ZWU&psig=AFQjCNGgHg6v1F4apCaRkGaEUZJXn2ZAUA&ust=1362653019967823�

MACHINING INJECTION / MOLDING

Very high precision o Long time and higher price

needed if complex part o Need to replace tool when worn o Geometrical restriction due to

tool access o A lot of waste material o Sometimes several steps to have

the final part o Single material parts

High production rate o 1 mold = 1 part model o Long test period to find good

parameters o Complex fluid dynamic

(shrinkage, solidification rate,…) o An error at the early beginning

have a very expensive impact o Strong geometrical limitations o Single material parts


AM try to solution these problems since 1990 : Only the required material is used. To increase the geometrical complexity, a layer-by-layer building fashion

is chosen. No tools are used. The complexity doesn’t increase the cost. Very different parts (size, complexity,... even color !) can be built together

in a same job, and even be added during processing. Some technologies allow multi-materials parts in one shot. Functionalities can be added (hinges, spring, gears,…) The delay is usually a week, compared to several months with the

traditional ways Customization can be used at its highest level Weight reduction is far more easy than before (lattice) Texturing, conformal cooling, internal cavities,… Organized by SIRRIS the 12th of March 2013 Masterclass: Biomedical applications of Additive Manufacturing 5

- Is it just perfect ? – Almost : Part size limitation : 250 x 250 x 300 mm as mean vol (max 2000 mm). Minimum wall thickness : 0,3 -> 1,5 mm Surface quality : Ra ~10 – 20 µm Anisotropy of mechanical properties due to layer-by-layer The raw material (usually powder) is surrounding the part after the

process. Inside and outside… So It could be hard to remove it from a very narrow and long channel.

With metal powder or liquid photosensitive polymer, supports are required. They are built in the same time than the part and act as an anchorage. They will keep the part in place. They have to be removed after the process and damage a bit the surface quality in the contact zone => small post-machining often required.


- But how does it work ? What means “layer-by-layer” ? Everything starts from the CAD file of the part (.iges, .stp) which is

converted in the .stl format, proper to AM technologies. This file is virtually placed in the building chamber of the process :


The “layers” of the job (all the virtual parts into the building chamber) are then automatically generated vertically and the resulting slices of the part are stored in another file proper to each technology manufacturer.


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Now the goal is to convert this virtual slices in a stack of real slices into solid material and to combine them together to have the desired part :


Virtual world Real world

AM machine

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http://www.google.be/url?sa=i&rct=j&q=analysing&source=images&cd=&cad=rja&docid=o2afbGUbqbHxoM&tbnid=OtF_fudbgHwjiM:&ved=0CAUQjRw&url=http://www.invictaproperties.ca/5-easy-mistakes-to-avoid-when-analysing-a-deal&ei=RN05UfKJFeWW0QW-jYFo&bvm=bv.43287494,d.d2k&psig=AFQjCNFGek1vBeAmQaXypheEHvEKuSMtAg&ust=1362833075003037�

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To convert a virtual slice to a real one, the machine simply spreads a thin layer of raw material (let’s say in powder form) over all the bottom of the working chamber. Then the machine analyze the first slice to “materialize” and reproduce it on the layer spread in 2D. It agglomerates the raw material in the area described on the virtual slice.


Top view of the virtual slice, areas

to agglomerate Fresh new layer

of powder

Agglomeration of the specified

areas

Completed slice

LBM process description :

Masterclass: Biomedical applications of Additive Manufacturing 11 Organized by SIRRIS the 12th of March 2013

Spread powder

Recoater

Laser beam

Melted zones

Previous layers

Initial plate

Argon

Main tank

Let’s begin with the simplest one, the 3D printing of plaster powder with color functionalities.

1. The powder is spread over the workplate by a roller 2. The printing head deposit a binder on the areas specified by the slices,

and color on contours


roller

powder

Work plate

Zone without binder Zone with binder

Printing head

Printing head

Powder grain

layer

Binder droplets

These are the kind of parts produced with 3D printer from Z Corporation :


http://www.google.be/url?sa=i&rct=j&q=Z+croporation&source=images&cd=&cad=rja&docid=nipAuQm0oPZ20M&tbnid=g9A0wbC6RgpAoM:&ved=0CAUQjRw&url=http://develop3d.com/blog/2011/02/z-corps-recycling-smarts&ei=a243UcWrO4aH0AXXr4CACQ&bvm=bv.43287494,d.ZWU&psig=AFQjCNG76-fabJpw4ta_-hhdFoplDhh-QA&ust=1362673561785250�

http://www.google.be/url?sa=i&rct=j&q=Z+croporation&source=images&cd=&cad=rja&docid=BHGpZY-8p1KE-M&tbnid=SuA2mW1MFj8GCM:&ved=0CAUQjRw&url=http://pclab.pl/news25199.html&ei=4243UcqHNYKf0QX4_oGYCA&bvm=bv.43287494,d.ZWU&psig=AFQjCNG76-fabJpw4ta_-hhdFoplDhh-QA&ust=1362673561785250�

It is possible to print metal (e.g. stainless steel) in 3D with a binder but the parts have to be post processed to replace the binder by a low melting temperature metal, such as bronze.

The processed green parts are placed in a oven and, by increasing the temperature, the bronze melt and the binder is degraded, leaving porosity in part which filled by the bronze by capillarity.


“green part” “brown part”

Infiltration Curing

Structure of the final part

Debinding As built

Some part produce by Prometal 3D printing process (60% stainless steel, 40% bronze) :


= > Can you make such parts with traditional technologies… in one or two week maximum ?

The small problem with the previous technology is the multi-material characteristic of the final part (glue or other metal). How can we have a part made of only one material ? So they replace the printing head by a laser driven by a set of lens and mirrors which melt the powder, exactly like welding. This is the LBM process :


When the raw material in a polymer (ABS, polyamide, PVC,…) this is quite easy and you can but part wherever you want in the volume of the work chamber, the powder itself is enough to support the part.


Magics software from Materialise

Here are some parts made of polymer with LBM technology :


http://www.google.be/url?sa=i&rct=j&q=laser+sintering&source=images&cd=&cad=rja&docid=qLF2-nnWOXWf6M&tbnid=5WheOnpSsHNwcM:&ved=0CAUQjRw&url=http://www.rpworld.net/cms/index.php/additive-manufacturing/rp-rapid-prototyping/sls-selective-laser-sintering.html&ei=6Hc3UbXTCMahO6b0gYAI&bvm=bv.43287494,d.ZWU&psig=AFQjCNGUcj5JgfetanL50O9dy6F4DdZgtA&ust=1362676056374259�

http://www.google.be/url?sa=i&rct=j&q=laser+sintering&source=images&cd=&cad=rja&docid=iw-Gq59s9Rhm0M&tbnid=St566x6vbP9DZM:&ved=0CAUQjRw&url=http://encyclopedia2.thefreedictionary.com/laser+sintering&ei=LXg3UfnEFIKWO-yTgKgI&bvm=bv.43287494,d.ZWU&psig=AFQjCNGUcj5JgfetanL50O9dy6F4DdZgtA&ust=1362676056374259�

http://www.google.be/url?sa=i&rct=j&q=laser+sintering&source=images&cd=&cad=rja&docid=aM2UW-iVsmunaM&tbnid=vwF5SxFul2JBRM:&ved=0CAUQjRw&url=http://www.diytrade.com/china/pd/10541998/GPolymers_SLS_selective_laser_sintering_of_Polyamide_12_powder.html&ei=k3g3UZTND4LYPYrggZgG&bvm=bv.43287494,d.ZWU&psig=AFQjCNGUcj5JgfetanL50O9dy6F4DdZgtA&ust=1362676056374259�

With metal powder in LBM, there are more barriers to produce parts : Due to stronger thermal stresses that occurs during welding, the parts

tend to be deformed. The higher laser power induce higher heat input and the powder doesn’t

take it away as efficiently as bulk material For those reasons, supports have to be added to the CAD file of the part to

prevent deformation and drive the heat away. To ensure this anchorage, supports of the part are directly welded on the thick removable working plate :


Supports are a necessary evil in LBM but : If there are in hard-to-reach zone, it’s very complicated to remove them after the

process. If they support a very thin structure, this latter can be distorted during removing. The surface contact between supports and part has a worse surface quality which will

required post machining.

They consume the silicone wiper of the recoater quicker than “part” area. So more supports you have, worse is the flatness of the last layers.

This is an additional material cost. Some design and positioning rules can reduce the amount of supports

needed.


Some parts made of metal with LBM technology :


http://www.google.be/url?sa=i&rct=j&q=Selective+laser+melting&source=images&cd=&cad=rja&docid=RtYOs5psNDPnOM&tbnid=Y4AYSZ-raOeNhM:&ved=0CAUQjRw&url=http://www.realizer.com/&ei=sYI3UbOGHYqD4ATn3IHYCw&psig=AFQjCNEKrbQhRMMRzbLQPUZRdTzn8bgh7w&ust=1362678771777584�

Another technology use the same principle but with an electron beam. So it works under vacuum conditions and the work plate is heated at high temperature (~600°C) which reduce the thermal stresses and, so, supports are less (not) needed :


http://www.google.be/url?sa=i&rct=j&q=ebm+arcam&source=images&cd=&cad=rja&docid=twzcdDBZE6VJhM&tbnid=8w1fyulUHqBaMM:&ved=0CAUQjRw&url=http://www.sirris.be/newsItem.aspx?id=14328&LangType=2060&ei=J5s4UdrnBKf80QWZjYGgCQ&bvm=bv.43287494,d.ZWU&psig=AFQjCNGM4rTlXQj_0ZneKFCcNrBAjU_IeQ&ust=1362750613673353�

http://www.google.be/url?sa=i&rct=j&q=ebm+arcam&source=images&cd=&cad=rja&docid=IxVJQPSKRJHbTM&tbnid=x5BLZyllHb-5LM:&ved=0CAUQjRw&url=http://www.eetimes.com/General/PrintView/4013703&ei=tZs4Ufj2M8uS0QXjooGoCA&bvm=bv.43287494,d.ZWU&psig=AFQjCNGM4rTlXQj_0ZneKFCcNrBAjU_IeQ&ust=1362750613673353�

http://www.google.be/url?sa=i&rct=j&q=titanium+parts+additive+manufacturing&source=images&cd=&cad=rja&docid=hmKtM-P-LoPnLM&tbnid=6IrERRvu1ozgrM:&ved=0CAUQjRw&url=http://www.micromanufacturing.com/node/3202&ei=XK44UdyNOrLB0gXvmIHICA&psig=AFQjCNEtD6IOWVjsOYgSj6I4LL70Q7Tx0g&ust=1362751773783164�

http://www.google.be/url?sa=i&rct=j&q=titanium+parts+additive+manufacturing&source=images&cd=&cad=rja&docid=uI2JixZxVY5z-M&tbnid=wEhfIcRvk63JqM:&ved=0CAUQjRw&url=http://www.3ders.org/articles/20130118-3-meter-long-titanium-airplane-part-3d-printed-in-one-piece.html&ei=a684UYXAKsi_0QW1pIGICQ&psig=AFQjCNEtD6IOWVjsOYgSj6I4LL70Q7Tx0g&ust=1362751773783164�

In every previous technologies, a recoater is needed to spread the powder over the flat workplate. But it is also possible to add features (coating, local repair, additional geometry,… ) on a non-flat surface with another principle : replace the drill of a CNC machine with a material deposition nozzle. Powder is blown through a laser beam thanks to that nozzle and this allow 5-axis welding. The superposition of tracks can make 3D shapes


Carrier gas + powder

Shape Gas

Laser + central gaz (coaxial)

Substrate

Meltpool Track

Heat Affected Zone

Motion direction

This process is called Laser Metal Deposition. Thank to multiple axis, it is possible to bring the material wherever on a surface and locally increase mechanical properties, repair a damage area or reload a wearing part :


ICE Pototyping (LENS)

IWS fraunhofer

Fraunhofer center for surface and laser processing

IRIS

http://www.google.be/url?sa=i&rct=j&q=laser+metal+deposition&source=images&cd=&cad=rja&docid=z2zUjh-t_jL7fM&tbnid=_rwlAJYD8Ru9pM:&ved=0CAUQjRw&url=http://www.afas.org.au/vic/events/2007/laser.htm&ei=i7g4UZ2EM8mu0QXd1YDYBw&bvm=bv.43287494,d.ZWU&psig=AFQjCNFmemgNl0yKbUDovfknbIGVuyBMEA&ust=1362758047018449�

The oldest system is working from liquid a photosensitive raw material. The principle is the same as LBM. The drilled workplate is gradually plunged in a tank of resin. The liquid surface is leveled by a wiper between each downward movement and a UV laser polymerize the resin in the specified areas. This process need a UV curing to finish polymerization

Masterclass: Biomedical applications of Additive Manufacturing 25

Liquid polymer

supports

workplate

Liquid displacements

part

wiper

Organized by SIRRIS the 12th of March 2013

Here are some examples made in Stereolithography :


http://www.google.be/url?sa=i&rct=j&q=stereolithography&source=images&cd=&cad=rja&docid=o9eHkC0jS9xDuM&tbnid=5ukJxK4yxt2GwM:&ved=0CAUQjRw&url=http://www.carriocabling.com/stereolithography_prototyping_sla.html&ei=Wwo6UZz0Fqqb0QX944GwAQ&bvm=bv.43287494,d.ZGU&psig=AFQjCNHd3eQqUi_9IHMEvYTNKB6p7Lnhog&ust=1362844466879303�

http://www.google.be/url?sa=i&rct=j&q=Stereolithography&source=images&cd=&cad=rja&docid=MAZtLKlXCiP_XM&tbnid=-Dg6dsbZDy4KuM:&ved=0CAUQjRw&url=http://www.vectorpraxis.com/digital-fabrication-buzz-and-buzzkill/&ei=vAo6UbT6O8fX0QWlwoC4Bw&bvm=bv.43287494,d.ZGU&psig=AFQjCNH4WqrtaDCgFUYxJCmmu6hDHHvONA&ust=1362844669488374�

http://www.google.be/url?sa=i&rct=j&q=Stereolithography&source=images&cd=&cad=rja&docid=3dd47Itf7orB7M&tbnid=jCx6URDeY3aE1M:&ved=0CAUQjRw&url=http://www.paragon-rt.com/stereolithography/&ei=gQs6Uc3fBdCX0QXfvIGQDg&bvm=bv.43287494,d.ZGU&psig=AFQjCNH4WqrtaDCgFUYxJCmmu6hDHHvONA&ust=1362844669488374�

http://www.google.be/url?sa=i&rct=j&q=Stereolithography&source=images&cd=&cad=rja&docid=c97UIGIz0PcUOM&tbnid=0yNdqxSkOcKi7M:&ved=0CAUQjRw&url=http://manufacturing.materialise.com/mammoth-stereolithography-0&ei=0gs6UfK1O4nK0QXR3YGQBg&bvm=bv.43287494,d.ZGU&psig=AFQjCNH4WqrtaDCgFUYxJCmmu6hDHHvONA&ust=1362844669488374�

http://www.google.be/url?sa=i&rct=j&q=Stereolithography&source=images&cd=&cad=rja&docid=PUsBSS2EfUFtxM&tbnid=NPEPOKKq3tVGtM:&ved=0CAUQjRw&url=http://www.asminternational.org/content/ASM/PortletImages/Emails/AMP/april232008/enews04232008.html&ei=SQw6UajbMISX1AWf7ICYDA&bvm=bv.43287494,d.ZGU&psig=AFQjCNH4WqrtaDCgFUYxJCmmu6hDHHvONA&ust=1362844669488374�

3D Objet printing : mix between 3D printing and stereolithography. The printing head deposits à photosensitive resin in specified areas. The deposition is directly followed by a polymerization with a UV laser mounted on the same support than the printing head.


http://www.google.be/url?sa=i&rct=j&q=Objet+connex&source=images&cd=&cad=rja&docid=4z7fRO0jQAOQWM&tbnid=x-HI8iesg7aqCM:&ved=0CAUQjRw&url=http://www.3ders.org/articles/20120620-objet-break-the-100-material-range-barrier.html&ei=DRM6UZyYCYqx0AWRmYDIBA&bvm=bv.43287494,d.d2k&psig=AFQjCNFUG1mVzgQ55z3zrFcYbY3MGihh5g&ust=1362846852566072�

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http://www.google.be/url?sa=i&rct=j&q=Objet+connex&source=images&cd=&cad=rja&docid=h3cjWUcCxJUmuM&tbnid=i9BvmikLf3azNM:&ved=0CAUQjRw&url=http://www.core77.com/blog/technology/objet_geometries_260_connex_3d_printer_puts_two_different_materials_in_one_rpd_object_19866.asp&ei=gBM6UbTVPKOf0QX7t4HwAw&bvm=bv.43287494,d.d2k&psig=AFQjCNFUG1mVzgQ55z3zrFcYbY3MGihh5g&ust=1362846852566072�

http://www.google.be/url?sa=i&rct=j&q=Objet+connex&source=images&cd=&cad=rja&docid=imCGP6VQtMccyM&tbnid=CL1jOLH1_m8lHM:&ved=0CAUQjRw&url=http://www.sculptcad.com/product/single_product_details/10/5&ei=xRM6Ucr9Ba-b1AXSvYHoCw&bvm=bv.43287494,d.d2k&psig=AFQjCNFUG1mVzgQ55z3zrFcYbY3MGihh5g&ust=1362846852566072�

http://www.google.be/url?sa=i&rct=j&q=Objet+connex&source=images&cd=&cad=rja&docid=-h6lJanttJtDTM&tbnid=Nit6epkBfHioKM:&ved=0CAUQjRw&url=http://www.scoop.it/t/conception-innovation/p/1927692738/this-3d-printer-can-use-up-to-14-materials-make-3d-printing-more-flexible&ei=OhQ6UcScJOqK0AWV3IDgBg&bvm=bv.43287494,d.d2k&psig=AFQjCNFUG1mVzgQ55z3zrFcYbY3MGihh5g&ust=1362846852566072�

It is also possible to build in ceramics parts. This is a combination of SLM and stereolithography technologies. There isn’t a spreading of powder but a paste made of ceramic powder and a photosensitive polymer, like in SLM, but the laser doesn’t melt any material, it polymerizes the resine, like in stereolithography. After processing the parts, they are removed from the paste, cleaned and placed in a oven for sintering the ceramic and remove the polymer. Here are some examples :

Masterclass: Biomedical applications of Additive Manufacturing 28

Laser processing

Recoater

Slurry

Parts

Organized by SIRRIS the 12th of March 2013

Fused Deposition Modeling : A wire of solid polymer is push through a 3-axis heated nozzle which cause slightly melting. The solidification occurs by air cooling just after extrusion/deposition.


http://www.google.be/url?sa=i&rct=j&q=fused+deposition+modeling&source=images&cd=&cad=rja&docid=ZupMowknPW8fAM&tbnid=03Pb-MVrKXHlkM:&ved=0CAUQjRw&url=http://www.protoway.com/ENG/fdm_prototypes.html&ei=LxI6UYq8MOKy0QWin4CgDg&bvm=bv.43287494,d.d2k&psig=AFQjCNERAvi7DEmkA5oBDSQqkQNI935Ygg&ust=1362846538155835�

http://www.google.be/url?sa=i&rct=j&q=fused+deposition+modeling&source=images&cd=&cad=rja&docid=B_989PXjKACn6M&tbnid=tKu9WZq9-nJoPM:&ved=0CAUQjRw&url=http://www.xpress3d.com/FDM.aspx&ei=xBI6UaOiOYmS0QWY_IGoBQ&bvm=bv.43287494,d.d2k&psig=AFQjCNERAvi7DEmkA5oBDSQqkQNI935Ygg&ust=1362846538155835�

http://www.google.be/url?sa=i&rct=j&q=fused+deposition+modeling&source=images&cd=&cad=rja&docid=VKk7fzyT39WNkM&tbnid=wQ46G86S0tHmVM:&ved=0CAUQjRw&url=http://de.academic.ru/dic.nsf/dewiki/482408&ei=4BI6UbyyFfLv0gWO9YHQCQ&bvm=bv.43287494,d.d2k&psig=AFQjCNGiyltYaR6AmFXjt8WyL8MCDAWYdg&ust=1362846810974168�

Small summary of technologies :


3DP Z-Corp 3DP Prometal 3DP Objet 3DP Optoform

LBM EOS LBM SLM Solution EBM Arcam

LMD

Stereolithography

FDM Makerbot

http://www.google.be/url?sa=i&rct=j&q=Z+croporation&source=images&cd=&cad=rja&docid=BHGpZY-8p1KE-M&tbnid=SuA2mW1MFj8GCM:&ved=0CAUQjRw&url=http://pclab.pl/news25199.html&ei=4243UcqHNYKf0QX4_oGYCA&bvm=bv.43287494,d.ZWU&psig=AFQjCNG76-fabJpw4ta_-hhdFoplDhh-QA&ust=1362673561785250�

http://www.google.be/url?sa=i&rct=j&q=Objet+connex&source=images&cd=&cad=rja&docid=4z7fRO0jQAOQWM&tbnid=x-HI8iesg7aqCM:&ved=0CAUQjRw&url=http://www.3ders.org/articles/20120620-objet-break-the-100-material-range-barrier.html&ei=DRM6UZyYCYqx0AWRmYDIBA&bvm=bv.43287494,d.d2k&psig=AFQjCNFUG1mVzgQ55z3zrFcYbY3MGihh5g&ust=1362846852566072�

http://www.google.be/url?sa=i&rct=j&q=titanium+parts+additive+manufacturing&source=images&cd=&cad=rja&docid=hmKtM-P-LoPnLM&tbnid=6IrERRvu1ozgrM:&ved=0CAUQjRw&url=http://www.micromanufacturing.com/node/3202&ei=XK44UdyNOrLB0gXvmIHICA&psig=AFQjCNEtD6IOWVjsOYgSj6I4LL70Q7Tx0g&ust=1362751773783164�

http://www.google.be/url?sa=i&rct=j&q=stereolithography&source=images&cd=&cad=rja&docid=o9eHkC0jS9xDuM&tbnid=5ukJxK4yxt2GwM:&ved=0CAUQjRw&url=http://www.carriocabling.com/stereolithography_prototyping_sla.html&ei=Wwo6UZz0Fqqb0QX944GwAQ&bvm=bv.43287494,d.ZGU&psig=AFQjCNHd3eQqUi_9IHMEvYTNKB6p7Lnhog&ust=1362844466879303�

http://www.google.be/url?sa=i&rct=j&q=fused+deposition+modeling&source=images&cd=&cad=rja&docid=ZupMowknPW8fAM&tbnid=03Pb-MVrKXHlkM:&ved=0CAUQjRw&url=http://www.protoway.com/ENG/fdm_prototypes.html&ei=LxI6UYq8MOKy0QWin4CgDg&bvm=bv.43287494,d.d2k&psig=AFQjCNERAvi7DEmkA5oBDSQqkQNI935Ygg&ust=1362846538155835�


Metal technologies :

LBM EBM LMD 3DP Size (mm) 250 x 250 x 350 210 x 210 x 350 900 x 980 x 500 1000 x 500 x 250

Layer thickness (µm) 30 - 60 50 130 - 600 70 - 170

Min wall thickness (mm) 0.2 0.3 0.6 0.75

Accuracy (mm) +/- 0.2 or 0.1% +/- 0.13 – 0.2 N.A. 0.2 - 0.3

Build rate (cm³/h) 5 - 20 10 – 40 (lattices 80) 2 - 30 Up to 120

Surface roughness (µm) 5 - 15 15 - 35 15 - 20 20 - 30

Geometry limitations Supports needed everywhere (thermal,

anchorage)

Very few supports but rest of the powder no

more fluid but pre-sintered as a “cake”

No powder bed. Same limitations as 5 axes

milling.

No support. Almost no limitation.

materials Stainless steel, tool steel, titanium,

aluminum,…

Only conductive materials (Ti6Al4V,

CrCo,…)

Every powdered materials.

SS 316L or 420 + bronze (standard)



0

2

4

6

8

10 size (mm³)

layer thickness (µm)

min wall thickness (mm)

Best accuracy (mm)

Build rate (cm³/h)

Best surface roughness (µm)

SLM

EBM

LMD

3DP








Polymer technologies :

LBM (EOS) 3DP (Z-corp) STL (Viper Si2)

3DP (Connex 500)

FDM (Makerbot)

Size (mm) 350 x 350 x 630 (P390)

250 x 350 x 200 250 x 250 x 250 500 x 400 x 200 225 x 145 x 150 (Makerbot)

Layer thickness (µm) 100 - 150 100 25 - 150 16 - 30 100 - 300

Min wall thickness (mm)

0.6 – 0.7 2 - 3 0.2 – 0.3 0.5 – 0.6 2

Accuracy (mm) 0.2 - 0.2% > 100 mm 1 - 2 +-0.1 +-0.1 - Positioning : 11 µm

Geometry limitations Almost non Almost non Removing supports in

closed volume

Removing supports in closed volume

materials PA, PA+Al, PA+C Plaster powder Acrylate-based resins

Acrylate-based resins

ABS, PLA



0 1 2 3 4 5 6 7 8 9

10 size (mm³)

layer thickness (µm)

min wall thickness (mm)

Best accuracy (mm)

LBM EOS P390

3DP Z-Corp

STL Viper Si2

3DP Connex 500

FDM Makerbot






Summary : Z-corp : attractive demonstrators, cheap prototype, architecture, trendy

reasons. (color, powder, no support) 3DP Prometal : Stainless steel part with complex internal geometry and

“foundry” surface quality. (No heat input, powder, no support) 3DP Objet : Mutli-material polymer parts with high resolution and bending

functionalities. (multi-material nozzle, resin, supports needed) 3DP Optoform : Ceramic parts (HA, TCP, Zr,…) for bone implants mainly

(paste, supports needed, high shrinkage) LBM EOS : Polyamide parts for every applications (Powder, no support) Stereolithography : Transparent resins for every applications (Resin, supports

needed) FDM : Cheapest technology, medium quality (wire, supports needed) LBM SLM Solution : Most effective with thin metal parts. (powder, supports

needed) EBM Arcam : high build rate, well suited for massive parts (Powder, ~no

support) LMD : repair, local coating, graded material on non flat surface (powder,

limited 3D complexity)

Design simplification :

From 12 components to only one with better efficiency :


Sirris

Medical prothesis :

Every patient is unique and needs, of course, a specific shape. Material properties have to be adapted to the bone to preserve it :


http://www.medicaldevice-network.com/contractors/manufacturing/layerwise/�

Complex piping :


Sirris – compolight project

Articulated parts without assembly :


Barosens (Morris technology)

EOS

Objet 3D

Objet 3D

Oak Ridge National Laboratory

Materialise

http://www.google.be/url?sa=i&rct=j&q=articulated+additive+manufacturing+parts&source=images&cd=&cad=rja&docid=zr-YMRPwJFNgLM&tbnid=yqgn3H2HvaksWM:&ved=0CAUQjRw&url=http://www.mmsonline.com/articles/movable-components-no-assembly-required&ei=EEQJUZSSFeW10QXXxYD4Bg&bvm=bv.41642243,d.bGE&psig=AFQjCNHG7pOQ2sHS1rzhfLbIIlxPDyvuWw&ust=1359648126707959�

Lightweight parts :


Within Technology

EOS

EADS

Laser Cusing Sirris – compolight project

http://www.google.be/url?sa=i&rct=j&q=lightweight+parts+additive+manufacturing&source=images&cd=&cad=rja&docid=0WRlrVxmcR-YsM&tbnid=Jqtygv6LnyQ0hM:&ved=0CAUQjRw&url=http://within-lab.com/blog/?tag=additive-manufacturing&ei=8D0JUa7MCsiK0AWdhIDgBA&psig=AFQjCNGPiw7DCjP2Uez4k-SsfQjlezK3vA&ust=1359646392060960�

Jewelry:


Shapeways

http://www.eos.info/javasc�

http://www.eos.info/javasc�

Customization :


Olaf Diegel Sirris (Driessen & Verstappen)

Materialise

Sirris (YAMM)

Conformal cooling :


Before AM With AM Part to produce by injection

• Conventional cycle time: 38s

• CCC cycle time: 32s

• Reducing cycle time: 16%

• Profit for the 1st year: 222.000 € (6.000.000 units/year)

You can have a part within a week. A lot of different materials are available. AM let you make quickly a first prototype to validate a concept and avoid

future mistake. A lot of functionalities can be added to your part (hinges, spring,

lightweight, conformal cooling, local coating, multi-material,…) The complexity doesn’t increase the price. Highest degree of customization.

Don’t forget that supports are sometimes required. Parts are surrounded by powder /resin/paste which has to be removed. Post machining or polishing is often required after the process.


=> Thank you for you attention ! Magnien Julien